Device and method for manufacturing membrane-electrode assembly of fuel cell

ABSTRACT

A manufacturing device of a membrane-electrode assembly for a fuel cell bonds each of anode and cathode catalyst electrode layers continuously formed in upper and lower electrode films to upper and lower surfaces of an electrolyte membrane. The device includes: upper and lower bonding rolls respectively installed to upper and lower sides of a transport path of the electrolyte membrane and of the upper and lower electrode films, the bonding rolls pressing the catalyst electrode layers to the upper surface and the lower surface of the electrolyte membrane at a predetermined temperature to be transferred, and upper and lower adsorbents respectively disposed at the upper and lower sides of the transport path in an entry side of the upper and lower bonding rolls, installed to be reciprocally moved along the transport path, and selectively adsorbing the upper and lower electrode films.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 14/934,677, filed on Nov. 6, 2015, which claims priority to andthe benefit of Korean Patent Application No. 10-2015-0107528, filed onJul. 29, 2015. The entirety of all of related applications are herebyincorporated by reference.

FIELD

An exemplary embodiment of the present disclosure relates to a systemfor manufacturing parts of a fuel cell stack, and manufacturing amembrane-electrode assembly for a fuel cell.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Fuel cells produce electricity through an electrochemical reactionbetween hydrogen and oxygen. Fuel cells may continuously generateelectric power upon receiving a chemical reactant from the outside, evenwithout a separate charging process.

A fuel cell may be formed by disposing separators (or bipolar plates) onboth sides of a membrane-electrode assembly (MEA) interveningtherebetween. A plurality of fuel cells may be continuously arranged toform a fuel cell stack.

Here, a membrane-electrode assembly that is an example of a corecomponent of the fuel cell as a three-layer structure, includes anelectrolytic membrane in which hydrogen ions transfer, an anode catalystelectrode layer formed on one surface of the electrolytic membrane, anda cathode catalyst electrode layer formed on the other surface of theelectrolytic membrane. A direct coating method and a decal method areexamples of a method of manufacturing the three-layer structuremembrane-electrode assembly.

Among them, in the case of the decal method, an electrode film coatedwith each catalyst electrode layer is deposited on both surfaces of theelectrolyte membrane, the catalyst electrode layer is transferred toboth surfaces of the electrolyte membrane to be joined, and then theelectrode film is removed, thereby manufacturing the membrane-electrodeassembly of a three-layer structure.

That is, in the manufacturing process of the membrane-electrode assemblyusing the decal method, an electrode film of a roll type coated witheach catalyst electrode layer and an electrolyte membrane of a roll typepass a bonding roll of high temperature and high pressure to belaminated (thermally compressed), and the electrode film is removed tomanufacture the membrane-electrode assembly of the three-layerstructure.

As described above, in the process of manufacturing themembrane-electrode assembly of the three-layer structure by the decalmethod using the roll laminating process, there are advantages inproduction with glass since a manufacturing speed may be improved.

However, in the decal method using the roll lamination process, in thestate that the electrode film coated with each catalyst electrode layeron both sides of the electrolyte membrane interposed therebetween ispositioned, since they pass between the bonding rolls of hightemperature and high pressure and the catalyst electrode layer and theelectrolyte membrane are laminated in the directions such that theycontact each other, we have discovered that it is difficult to align thelamination positions of the anode catalyst electrode layer and thecathode catalyst electrode layer.

That is, the electrode film and the electrolyte membrane continuouslypass between the bonding rolls of high temperature and high pressurethat are pressed and the catalyst electrode layer is laminated on bothsurfaces of the electrolyte membrane, and in this roll laminatingcontinuous process, we have discovered that it is difficult to correctlyaccord the lamination positions of the catalyst electrode layers by afeeding speed difference of the electrode film.

We have further discovered that the lamination positions of the anodecatalyst electrode layer and the cathode catalyst electrode layer aredifficult to align because a pitch between the catalyst electrode layersis not constant in the process of manufacturing the catalyst electrodelayer of the continuous patterns by coating the catalyst slurry to theelectrode film.

SUMMARY

The present disclosure provides a device and a method of amembrane-electrode assembly for a fuel cell for aligning a transferposition of the catalyst electrode layer through a simple configurationwithout a change of the bonding roll while continuously roll-laminatingthe catalyst electrode layer to both surfaces of the electrolytemembrane by the decal method.

A manufacturing device of a membrane-electrode assembly for a fuel cellbonding each of anode and cathode catalyst electrode layers continuouslyformed in upper and lower electrode films to upper and lower surfaces ofan electrolyte membrane according to an exemplary embodiment of thepresent disclosure includes: upper and lower bonding rolls respectivelyinstalled to upper and lower sides of a transport path of theelectrolyte membrane and the upper and lower electrode films andpressing the catalyst electrode layer to the upper surface and the lowersurface of the electrolyte membrane at a predetermined temperature to betransferred; and upper and lower adsorbents respectively disposed at theupper and lower sides of the transport path in an entry side of theupper and lower bonding rolls, installed to be reciprocally moved alongthe transport path, and selectively adsorbing the upper and lowerelectrode films.

Upper and lower position sensors respectively installed at the upper andlower sides of the transport path in the entry side of the upper andlower adsorbents, sensing the position of the catalyst electrode layerof the upper and lower electrode films, and outputting a detectionsignal of the position to a controller may be further included.

The upper and lower adsorbents may be formed with air holes tovacuum-adsorb the upper and lower electrode films.

The upper and lower adsorbents may be formed with the air holes at thesurface corresponding to the upper and lower electrode films and is madeof a plate type case having a closed and sealed space inside.

The upper and lower adsorbents may be respectively connected to a vacuumpump.

The upper and lower adsorbents may be installed to a base frame to bereciprocally moved along the transport path.

The base frame may be provided with a driver installed to berespectively connected to the upper and lower adsorbents andreciprocally moving the upper and lower adsorbents along the transportpath.

The driver may include a servo motor installed at the base frame, a leadscrew connected to the servo motor, a moving block coupled to the upperand lower adsorbents and engaged to the lead screw, and a guide blockinstalled at the base frame and reciprocally slide-moving the movingblock along the transport path.

The controller may control the operation of the vacuum pump and thedriver due to a detection signal transmitted from the upper and lowerposition sensors.

A manufacturing method of a membrane-electrode assembly for a fuel cellbonding each of anode and cathode catalyst electrode layers continuouslyformed in upper and lower electrode films to upper and lower surfaces ofan electrolyte membrane according to another exemplary embodiment of thepresent disclosure includes: unwinding the electrolyte membrane of aroll shape to be supplied to a predetermined transport path; unwindingthe upper and lower electrode films of the roll shape continuouslycoated with the anode and cathode catalyst electrode layers with apredetermined interval to be supplied to upper and lower sides of theelectrolyte membrane; sensing a position of the catalyst electrode layerfor the upper and lower electrode films through the upper and lowerposition sensors to output a detection signal thereof to the controller;operating a vacuum pump connected to any one among the upper and loweradsorbents and the driver, depending on the detection signal of theupper and lower position sensors through the controller;vacuum-adsorbing any one among the upper and lower electrode filmsthrough any one adsorbent and moving the adsorbent through the driver inthe feed direction of the electrolyte membrane and the upper and lowerelectrode films to align the position of the catalyst electrode layer;and transferring the catalyst electrode layer of the upper and lowerelectrode films to the upper surface and the lower surface of theelectrolyte membrane at a predetermined temperature while passing theelectrolyte membrane and the upper and lower electrode films between theupper and lower bonding rolls.

The controller may calculate a position difference value of the catalystelectrode layer depending on a driving speed of the upper and lowerelectrode films with reference to a position sensing time difference ofthe upper and lower position sensors, and may apply an operation controlsignal to the vacuum pump connected to any one of the upper and loweradsorbents and the driver when the position difference value is not 0.

The controller may apply the operation control signal to the vacuum pumpconnected to any one of the upper and lower adsorbents and the driverwith reference the detection signal of the upper and lower positionsensors firstly sensing the position of the catalyst electrode layer ofthe upper and lower electrode films.

The controller may apply the operation control signal to the vacuum pumpconnected to the upper adsorbent and the driver if the detection signalof the lower position sensor is first received.

The upper adsorbent may vacuum-adsorb the upper electrode film by thevacuum pump, and the driver may move the upper adsorbent by a distancecorresponding to the position difference value along the feed directionof the electrolyte membrane and the upper and lower electrode films.

The controller may apply the operation control signal to the vacuum pumpto stop the operation of the vacuum pump when the position differencevalue is 0, and may apply the operation control signal to the driver toreturn the upper adsorbent to the predetermined initial position throughthe driver.

The controller may apply the operation control signal to the vacuum pumpconnected to the lower adsorbent and the driver if the detection signalof the upper position sensor is first received.

The lower adsorbent may vacuum-adsorb the lower electrode film by thevacuum pump, and the driver may move the lower adsorbent by the distancecorresponding to the position difference value along the feed directionof the electrolyte membrane and the upper and lower electrode films.

The controller may apply the operation control signal to the vacuum pumpto stop the operation of the vacuum pump when the position differencevalue is 0, and may apply the operation control signal to the driver toreturn the lower adsorbent through the driver to the predeterminedinitial position.

The upper and lower position sensors may photograph each catalystelectrode layer for the upper and lower electrode films, and output thedata thereof to the controller.

The controller may analyze the vision data transmitted from the upperand lower position sensors to calculate a position difference value ofthe catalyst electrode layer for the upper and lower electrode films,and may apply the operation control signal to the vacuum pump connectedto any one of the upper and lower adsorbents and the driver when theposition difference value is not 0.

In an exemplary embodiments of the present disclosure, by forcedlytransferring the upper and lower electrode films through the upper andlower adsorbents, without the position of the upper and lower bondingroll, the transfer position of the anode catalyst electrode layer andthe cathode catalyst electrode layer for the electrolyte membrane areautomatically aligned to manufacture the membrane-electrode assembly.

Accordingly, in an exemplary embodiment of the present disclosure, sincethe position deviation of the catalyst electrode layer depending on thedriving speed difference of the upper and lower electrode films and thecoating position distribution of the catalyst electrode layer may becorrected, the transfer uniformity of the catalyst electrode layer maybe improved, a good quality of the membrane-electrode assembly may beobtained, and the productivity of the membrane-electrode assembly may befurther improved.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 is a view schematically showing a manufacturing device of amembrane-electrode assembly for a fuel cell according to an exemplaryembodiment of the present disclosure;

FIG. 2 is a view schematically showing a membrane-electrode assemblymanufactured by an automatic system including a manufacturing device ofa membrane-electrode assembly for a fuel cell according to an exemplaryembodiment of the present disclosure;

FIG. 3 is a perspective view of upper and lower adsorbents applied to amanufacturing device of a membrane-electrode assembly for a fuel cellaccording to an exemplary embodiment of the present disclosure;

FIG. 4 is a cross-sectional schematic diagram of upper and loweradsorbents applied to a manufacturing device of a membrane-electrodeassembly for a fuel cell according to an exemplary embodiment of thepresent disclosure;

FIG. 5 is a view schematically showing a driver to move upper and loweradsorbents applied to a manufacturing device of a membrane-electrodeassembly for a fuel cell according to an exemplary embodiment of thepresent disclosure; and

FIG. 6 to FIG. 9 are views to explain a manufacturing method of amembrane-electrode assembly for a fuel cell according to an exemplaryembodiment of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

As those skilled in the art would realize, the described embodiments maybe modified in various different ways, all without departing from thespirit or scope of the present disclosure.

Further, in the drawings, a size and thickness of each element arearbitrarily represented for better understanding and ease ofdescription, and the present disclosure is not limited thereto.

In a detailed description, in order to distinguish the same constituentelements, first, second, etc., are used in names of constituent elementsand do not represent an order.

In addition, in the entire specification, unless explicitly described tothe contrary, the word “comprise” and variations such as “comprises” or“comprising” will be understood to imply the inclusion of statedelements but not the exclusion of any other elements.

In addition, the terms “unit”, “means”, “portion”, and “member”described in the specification indicate a unit of a comprehensiveconstituent element for performing at least one function or operation.

FIG. 1 is a view schematically showing a manufacturing device of amembrane-electrode assembly for a fuel cell according to an exemplaryembodiment of the present disclosure.

Referring to FIG. 1, a manufacturing device 100 of a membrane-electrodeassembly for a fuel cell according to an exemplary embodiment of thepresent disclosure may be applied to an automation system forautomatically and consecutively manufacturing parts of unit fuel cellsthat form a fuel cell stack.

The automatic system as shown in FIG. 2 is used to manufacture amembrane-electrode assembly 1 in which an anode catalyst electrode layer5 is formed at one surface (an upper surface in a drawing) of anelectrolyte membrane 3, a cathode catalyst electrode layer 7 is formedat the other surface (a lower surface in the drawing) of the electrolytemembrane 3, and a sub-gasket 9 is formed at each edge side of thecatalyst electrode layers 5 and 7.

The automatic system automatically realizes an entire manufacturingprocess of a membrane-electrode assembly 1 up to a bonding process of anelectrode membrane sheet in which the catalyst electrode layers 5 and 7are bonded to respective surfaces of the electrolyte membrane 3 andformed of a roll shape, a bonding process of the membrane-electrodeassembly sheet in which a sub-gasket 9 is bonded to the edge side ofeach catalyst electrode layer 5 and 7 of the electrode membrane sheetand formed of the roll shape, and a cutting process of themembrane-electrode assembly sheet.

For example, the automatic system may manufacture the electrode membranesheet of the three-layer structure in which each film continuouslycoated with the anode catalyst electrode layer 5 and the cathodecatalyst electrode layer 7 is deposited onto respective surfaces of theelectrolyte membrane 3 and each catalyst electrode layer 5 and 7 istransferred and bonded to the respective surfaces of the electrolytemembrane 3 by the roll-laminating method.

The automatic system may manufacture the membrane-electrode assemblysheet in which the electrode membrane sheet and the sub-gasket 9 arebonded while passing between hot rollers in the state that the electrodemembrane sheet wound in the roll shape is unwound, the sub-gasket 9wound in the roll shape is unwound, and the sub-gasket 9 is positionedonto both surfaces of the electrode membrane sheet.

Also, the automatic system may unwind the membrane-electrode assemblysheet wound in the roll shape and cut the membrane-electrode assembly asa unit type including the catalyst electrode layers 5 and 7, therebyfinally manufacturing the membrane-electrode assembly 1.

The manufacturing device 100 of the membrane-electrode assembly for thefuel cell according to an exemplary embodiment of the present disclosureapplied to the automatic system is used to manufacture the electrodemembrane sheet of the three-layer structure by the roll-laminatingmethod and the decal method.

As shown in FIG. 1, the present device 100 may unwind the electrolytemembrane 3 wound in the roll shape, unwind upper and lower electrodefilms 2 and 4 on which the anode and cathode catalyst electrode layers 5and 7 are continuously coated and wound in the roll shape, and maytransfer the catalyst electrode layers 5 and 7 to the upper and lowersurfaces of the electrolyte membrane 3, respectively, at a hightemperature and high pressure by the roll-laminating method.

Here, the electrolyte membrane 3 is wound to an unwinder roller (notshown in the drawing) in the roll-shaped roll, is unwound from theunwinder roller, and is fed along a predetermined transport path. Theupper and lower electrode films 2 and 4 are wound to the unwinder rollerin the roll shape, are unwound from the unwinder roller, and arerespectively fed to the side of the upper and lower surfaces of theelectrolyte membrane 3 interposed therebetween.

Also, in the state that the catalyst electrode layers 5 and 7 aretransferred onto the upper and lower surfaces of the electrolytemembrane 3, the upper and lower electrode films 2 and 4 are peeled by arelease bar 6 and are wound to a rewinder roller (not shown in thedrawing) in the roll shape. The electrode membrane sheet (not shown inthe drawing) in which the catalyst electrode layers 5 and 7 arerespectively bonded to the upper and lower surfaces of the electrolytemembrane 3 is wound to a rewinder roller (not shown in the drawing) inthe roll shape.

The manufacturing device 100 of the membrane-electrode assembly for thefuel cell according to an exemplary embodiment of the present disclosureis formed of the structure in which the catalyst electrode layers 5 and7 of the upper and lower electrode films 2 and 4 are continuouslyroll-laminated to the upper and lower surfaces of the electrolytemembrane 3 by the decal method and the transfer position of the catalystelectrode layer 5 and 7 are automatically aligned by the simpleconfiguration.

For this, the manufacturing device 100 of the membrane-electrodeassembly for the fuel cell according to an exemplary embodiment of thepresent disclosure includes upper and lower bonding rolls 11 and 12,upper and lower adsorbents 31 and 32, and upper and lower positionsensors 61 and 62.

These constituent elements are configured in the main frame of theautomatic system, and in this case, the main frame that is built in theupper and lower directions and supports each of the constituent elementsmay be configured by one frame or two or more partitioned frames.

The main frame may include various sub-elements to support theconstituent elements of the manufacturing device 100 such as a bracket,a bar, a rod, a plate, a housing, a case, a block, and the like.

However, since the various sub-elements are to install the constituentelements of the manufacturing device 100, which will be described, tothe main frame, the various sub-elements are generally referred to asthe main frame in the exemplary embodiment of the present disclosure.

In an exemplary embodiment of the present disclosure, as describedabove, the upper and lower bonding rolls 11 and 12 are used to pass theelectrolyte membrane 3 and the upper and lower electrode films 2 and 4along the transport path, to press them at the predetermined temperaturewith the high pressure, and to transfer the catalyst electrode layers 5and 7 of the upper and lower electrode films 2 and 4 to the upper andlower surfaces of the electrolyte membrane 3.

These upper and lower bonding rolls 11 and 12 are disposed at the upperand lower sides of the electrolyte membrane 3 and the transport path ofthe upper and lower electrode films 2 and 4, and are installed to themain frame by the motor (not shown in the drawing) to be rotatable.

The upper and lower bonding rolls 11 and 12 are rotated in oppositedirections and function as bonding rollers while pressing the upper andlower electrode films 2 and 4 positioned at the upper and lower sides ofthe electrolyte membrane 3.

FIG. 3 is a perspective view of upper and lower adsorbents applied to amanufacturing device of a membrane-electrode assembly for a fuel cellaccording to an exemplary embodiment of the present disclosure, and FIG.4 is a cross-sectional schematic diagram of upper and lower adsorbentsapplied to a manufacturing device of a membrane-electrode assembly for afuel cell according to an exemplary embodiment of the presentdisclosure.

Referring to FIG. 3 and FIG. 4 as well as FIG. 1, the upper and loweradsorbents 31 and 32 according to an exemplary embodiment of the presentdisclosure are used to selectively vacuum-adsorb the upper and lowerelectrode films 2 and 4 moving along the transport path.

The upper and lower adsorbents 31 and 32 are disposed at the upper andlower sides of the transport path of the electrolyte membrane 3 and theupper and lower electrode films 2 and 4 in the entry side of the upperand lower bonding rolls 11 and 12, and are installed to be reciprocallymoved along the transport path thereof.

Here, the entry side of the upper and lower bonding rolls 11 and 12 isdefined by a position before the electrolyte membrane 3, and the upperand lower electrode films 2 and 4 are transferred along the transportpath and enter between the upper and lower bonding rolls 11 and 12.

The upper and lower adsorbents 31 and 32 vacuum-adsorb the upper andlower electrode films 2 and 4 by a vacuum absorption force, and forthis, the upper and lower adsorbents 31 and 32 are formed with air holes37 to vacuum-adsorb the upper and lower electrode films 2 and 4.

For example, the upper and lower adsorbents 31 and 32 are provided withsquare-plate-type cases 33 and 34 having a closed and sealed space. Thesquare-plate-type cases 33 and 34 are formed with the air holes 37 inthe surface corresponding to the upper and lower electrode films 2 and4.

The upper and lower adsorbents 31 and 32 adsorb the air through the airholes 37, thereby vacuum-adsorbing the upper and lower electrode films 2and 4 by the vacuum pressure of the air. For this, the upper and loweradsorbents 31 and 32 are connected to vacuum pumps 41 and 42,respectively. The vacuum pumps 41 and 42 apply the vacuum pressure tothe inner space of the square-plate-type cases 33 and 34 for the upperand lower adsorbents 31 and 32.

These vacuum pumps 41 and 42 are formed as vacuum pumps that are wellknown in the art to which the present disclosure pertains to apply thevacuum pressure to the predetermined space, thus a detailed descriptionthereof is omitted in the present specification.

Meanwhile, the upper and lower adsorbents 31 and 32 according to anexemplary embodiment of the present disclosure are installed to bereciprocally moved along the transport path of the electrolyte membrane3 and the upper and lower electrode films 2 and 4 through a base frame45 provided in the main frame, as shown in FIG. 5.

The base frame 45 is provided with a driver 51 installed to berespectively connected to the upper and lower adsorbents 31 and 32 andto reciprocally move the upper and lower adsorbents 31 and 32 along thetransport path. The driver 51, as shown in FIG. 5, includes a servomotor 53, a lead screw 55, a moving block 57, and a guide block 59.

The servo motor 53 is installed to be fixed to the base frame 45 througha fixing block 54. The lead screw 55 is connected to the drive shaft ofthe servo motor 53.

The moving block 57 is coupled to the upper and lower adsorbents 31 and32 and is engaged to the lead screw 55. The guide block 59 is installedto be fixed to the base frame 45. The moving block 57 is coupled to theguide block 59 to be reciprocally/slide-moved along the transport pathof the electrolyte membrane 3 and the upper and lower electrode films 2and 4.

Accordingly, in an exemplary embodiment of the present disclosure, thelead screw 55 is rotated in the forward direction through the servomotor 53, and the moving block 57 may be slide-moved along the guideblock 59 along with the upper and lower adsorbents 31 and 32 in the feeddirection of the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4.

Also, in an exemplary embodiment of the present disclosure, if the leadscrew 55 is rotated in the reverse direction through the servo motor 53,the moving block 57 may be slide-moved along the guide block 59 alongwith the upper and lower adsorbents 31 and 32 in the direction oppositeto the feed direction of the electrolyte membrane 3 and the upper andlower electrode films 2 and 4.

Referring to FIG. 1, the upper and lower position sensors 61 and 62according to an exemplary embodiment of the present disclosure sense thepositions of the catalyst electrode layers 5 and 7 of the upper andlower electrode films 2 and 4 transferred along the transport path alongwith the electrolyte membrane 3 and output the detection signal thereofto a controller 90.

The upper and lower position sensors 61 and 62 are respectivelyinstalled at the upper and lower sides of the transport path of theelectrolyte membrane 3 and the upper and lower electrode films 2 and 4in the entry sides of the upper and lower adsorbents 31 and 32. Here,the entry side of the upper and lower adsorbent 31 and 32 is defined bya position before the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4 are transferred along the transport path andenter between the upper and lower adsorbents 31 and 32.

The upper and lower position sensors 61 and 62 may sense the position ofthe sensing target by using an optical device such as ultrasonic waves,laser, infrared, etc., and may sense the position of the sensing targetwhile photographing the sensing target.

These upper and lower position sensors 61 and 62 are formed as positionsensors that sense the position of a sensing target by using the opticaldevice or photographing the sensing target such that further detaileddescription of the configuration thereof is omitted in the presentspecification.

The controller 90 to control the overall operation of the present device100, for example, due to the detection signal transmitted from the upperand lower position sensors 61 and 62, may control the operation of thevacuum pumps 41 and 42 to apply the vacuum pressure to the upper andlower adsorbents 31 and 32 and the operation of the driver 51 moving theupper and lower adsorbents 31 and 32.

For this, the controller 90 may be realized by at least one processoroperated by a predetermined program, and the predetermined program maybe programed to perform a manufacturing method of the membrane-electrodeassembly for the fuel cell according to an exemplary embodiment of thepresent disclosure.

The operation of the controller 90 due to the detection signal of theupper and lower position sensors 61 and 62 and the operation of theupper and lower adsorbents 31 and 32 by the controller 90 will befurther described in detail through a manufacturing method of themembrane-electrode assembly of the fuel cell according to an exemplaryembodiment of the present disclosure.

Hereafter, the manufacturing method of the membrane-electrode assemblyof the fuel cell according to an exemplary embodiment of the presentdisclosure using the operation of the manufacturing device 100 of themembrane-electrode assembly for the fuel cell according to an exemplaryembodiment of the present disclosure and the manufacturing device 100will be described with reference to the above-disclosed drawings andaccompanying drawings.

FIG. 6 to FIG. 9 are views to explain a manufacturing method of amembrane-electrode assembly for a fuel cell according to an exemplaryembodiment of the present disclosure.

Referring to FIG. 6, firstly, in an exemplary embodiment of the presentdisclosure, as shown in FIG. 6, the electrolyte membrane 3 wound in theroll shape is unwound to be fed in the predetermined transport path, andthe upper and lower electrode films 2 and 4 wound in the roll shape areunwound to be fed to the upper and lower surfaces of the electrolytemembrane 3, respectively.

In this case, the upper and lower electrode films 2 and 4 arerespectively coated with the anode catalyst electrode layer 5 and thecathode catalyst electrode layer 7 corresponding to the upper and lowersurfaces of the electrolyte membrane 3.

In this process, in an exemplary embodiment of the present disclosure,the position of the catalyst electrode layers 5 and 7 for the upper andlower electrode films 2 and 4 is sensed through the upper and lowerposition sensors 61 and 62, and the detection signal is output to thecontroller 90.

Thus, the controller 90 calculates a position difference value of theanode catalyst electrode layer 5 and the cathode catalyst electrodelayer 7 depending on the driving speed of the upper and lower electrodefilms 2 and 4 with reference to a position sensing time difference ofthe upper and lower position sensors 61 and 62.

Here, if it is determined that the position difference value of theanode catalyst electrode layer 5 and the cathode catalyst electrodelayer 7 is not 0, with reference to the detection signal of the upperand lower position sensors 61 and 62 firstly sensing the position of thecatalyst electrode layers 5 and 7, the controller 90 applies theoperation control signal to the vacuum pump 41 and 42 connected to oneof the upper and lower adsorbent 31 and 32 and the driver 51.

For example, the controller 90 firstly receives the detection signal ofthe lower position sensor 62, and it is determined if the positiondifference value of the anode catalyst electrode layer 5 and the cathodecatalyst electrode layer 7 is “a” that is not “0”, the controller 90applies the operation control signal to the vacuum pump 41 connected tothe upper adsorbent 31 and the driver 51.

Accordingly, as shown in FIG. 7, the vacuum pump 41 is operated by thecontroller 90, and the vacuum pressure is applied to the inner space ofthe upper adsorbent 31. Thus, the upper adsorbent 31 adsorbs the airthrough the air holes 37 and the upper electrode film 2 is adsorbed bythe vacuum absorption force of this air.

Simultaneously, the driver 51 is operated by the controller 90, and theupper adsorbent 31 is moved along the feed direction of the electrolytemembrane 3 and the upper and lower electrode films 2 and 4 by thedistance corresponding to the position difference value a of the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7.

Here, the driver 51 operates the servo motor 53 through the controller90, and if the lead screw 55 is rotated in the forward direction, themoving block 57 may be slide-moved along the guide block 59 in the feeddirection of the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4, and the upper adsorbent 31 may be moved alongthe feed direction of the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4.

Accordingly, in the state that the upper adsorbent 31 vacuum-adsorbs theupper electrode film 2, the upper adsorbent 31 moves the upper electrodefilm 2 by the driver 51 along the feed direction of the electrolytemembrane 3 and the upper and lower electrode films 2 and 4 by thedistance corresponding to the position difference value a of the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7.

In this process, if it is determined that the position difference valueof the anode catalyst electrode layer 5 and the cathode catalystelectrode layer 7 due to the detection signal of the upper and lowerposition sensors 61 and 62 is “0”, the controller 90 applies theoperation control signal to the vacuum pump 41 to stop the operation ofthe vacuum pump 41. Thus, as the operation of the vacuum pump 41 isstopped, the upper electrode film 2 is free from the upper adsorbent 31.

Also, the controller 90 applies the operation control signal to thedriver 51 to return the upper adsorbent 31 through the driver 51 to thepredetermined initial position like in FIG. 6.

In this case, the driver 51 operates the servo motor 53 through thecontroller 90, and if the lead screw 55 is rotated in the reversedirection, the moving block 57 may be slide-moved along the guide block59 in the feed opposite direction of the electrolyte membrane 3 and theupper and lower electrode films 2 and 4, and the upper adsorbent 31 maybe moved in the initial position along the feed opposite direction ofthe electrolyte membrane 3 and the upper and lower electrode films 2 and4.

Meanwhile, as shown in FIG. 8, the controller 90 firstly receives thedetection signal of the upper position sensor 61, and if it isdetermined that the position difference value of the anode catalystelectrode layer 5 and the cathode catalyst electrode layer 7 is “b” thatis not 0, the controller 90 applies the operation control signal to thevacuum pump 42 connected to the lower adsorbent 32 and the driver 51.

Accordingly, as shown in FIG. 9, the vacuum pump 42 is operated by thecontroller 90, and the vacuum pressure is applied to the inner space ofthe lower adsorbent 32. Thus, the lower adsorbent 32 adsorbs the airthrough the air holes 37 and the lower electrode film 4 is adsorbed bythe vacuum absorption force of the air.

Simultaneously, the driver 51 is operated by the controller 90, and thelower adsorbent 32 is moved along the feed direction of the electrolytemembrane 3 and the upper and lower electrode films 2 and 4 by thedistance corresponding to the position difference value b of the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7.

Here, the driver 51 operates the servo motor 53 through the controller90, and if the lead screw 55 is rotated in the forward direction, themoving block 57 may be slide-moved along the guide block 59 in the feeddirection of the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4, and the lower adsorbent 32 may be moved alongthe feed direction of the electrolyte membrane 3 and the upper and lowerelectrode films 2 and 4.

Accordingly, in the state that the lower adsorbent 32 vacuum-adsorbs thelower electrode film 4, the lower adsorbent 32 moves the lower electrodefilm 4 by the driver 51 along the feed direction of the electrolytemembrane 3 and the upper and lower electrode films 2 and 4 by thedistance corresponding to the position difference value b of the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7.

In this process, if it is determined that the position difference valueof the anode catalyst electrode layer 5 and the cathode catalystelectrode layer 7 due to the detection signal of the upper and lowerposition sensors 61 and 62 is 0, the controller 90 applies the operationcontrol signal to the vacuum pump 42 to stop the operation of the vacuumpump 42. Thus, as the operation of the vacuum pump 42 is stopped, thelower electrode film 4 is free from the lower adsorbent 32.

Also, the controller 90 applies the operation control signal to thedriver 51 to return the lower adsorbent 32 through the driver 51 in thepredetermined initial position like in FIG. 8.

In this case, if the driver 51 operates the servo motor 53 through thecontroller 90 and the lead screw 55 is rotated in the reverse direction,the moving block 57 may be slide-moved along the guide block 59 in thefeed opposite direction of the electrolyte membrane 3 and the upper andlower electrode films 2 and 4, and the lower adsorbent 32 may be movedto the initial position along the feed opposite direction of theelectrolyte membrane 3 and the upper and lower electrode films 2 and 4.

Accordingly, in an exemplary embodiment of the present disclosure, inthe process that the upper and lower electrode films 2 and 4 face eachother via the electrolyte membrane 3 and are fed along the transportpath along the electrolyte membrane 3, the anode catalyst electrodelayer 5 and the cathode catalyst electrode layer 7 of the upper andlower electrode films 2 and 4 may be correctly matched due to thedriving speed difference of the upper and lower electrode films 2 and 4.

Accordingly, in an exemplary embodiment of the present disclosure, theupper and lower electrode films 2 and 4 are vacuum-adsorbed through theupper and lower adsorbents 31 and 32 and the upper and lower adsorbents31 and 32 may be moved in the feed direction of the electrolyte membrane3 and the upper and lower electrode films 2 and 4.

Accordingly, in an exemplary embodiment of the present disclosure, byforcefully feeding the upper and lower electrode films 2 and 4 throughthe upper and lower adsorbents 31 and 32, the transfer position of theanode catalyst electrode layer 5 and the cathode catalyst electrodelayer 7 for the electrolyte membrane 3 is aligned, and the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7may be correctly matched.

On the other hand, in an exemplary embodiment of the present disclosure,in the process of continuously coating the anode catalyst electrodelayer 5 and the cathode catalyst electrode layer 7 to the upper andlower electrode films 2 and 4, although the position deviation in whichthe pitch of the catalyst electrode layers 5 and 7 is not constant, thetransfer position of the anode catalyst electrode layer 5 and thecathode catalyst electrode layer 7 may be automatically aligned throughthe above-described process.

As described above, in the state that the transfer position of the anodecatalyst electrode layer 5 and the cathode catalyst electrode layer 7 isaligned, in an exemplary embodiment of the present disclosure, theelectrolyte membrane 3 and the upper and lower electrode films 2 and 4fed along the transport path enter between the upper and lower bondingrolls 11 and 12.

Thus, at the predetermined temperature, the upper and lower bondingrolls 11 and 12 are rotated in the directions opposite to each other andpress the electrolyte membrane 3 and the upper and lower electrode films2 and 4 in the high pressure, thereby the catalyst electrode layers 5and 7 of the upper and lower electrode films 2 and 4 are respectivelytransferred to the upper and lower surfaces of the electrolyte membrane3 to be bonded in the state that they are correctly matched.

In the above-described process, in an exemplary embodiment of thepresent disclosure, the controller 90 calculates the position differencevalue of the anode catalyst electrode layer 5 and the cathode catalystelectrode layer 7 depending on the driving speed of the upper and lowerelectrode films 2 and 4 with reference to the position sending timedifference of the upper and lower position sensor 61 and 62, however itis not limited thereto.

In another form, the upper and lower position sensors 61 and 62 mayphotograph the anode catalyst electrode layer 5 and the cathode catalystelectrode layer 7 for the upper and lower electrode films 2 and 4 andmay output the data thereof to the controller 90.

Thus, the controller 90 analyzes the data transmitted from the upper andlower position sensors 61 and 62 to calculate the position differencevalue of each anode catalyst electrode layer 5 and each cathode catalystelectrode layer 7 for the upper and lower electrode films 2 and 4.

Also, if it is determined that the position difference value of theanode catalyst electrode layer 5 and the cathode catalyst electrodelayer 7 is not 0, the controller 90 may apply the operation controlsignal to the vacuum pump 41 and 42 connected to one of the upper andlower adsorbent 31 and 32 and the driver 51 with reference to any onecatalyst electrode layer among the upper and lower electrode films 2 and4 linearly driving along the driving speed of the upper and lowerelectrode films 2 and 4.

For example, if it is determined that the lower electrode film 4 islinearly driven and the position difference value of the anode catalystelectrode layer 5 and the cathode catalyst electrode layer 7 is not 0,the controller 90 may apply the operation control signal to the vacuumpump 41 connected to the upper adsorbent 31 and the driver 51.

Also, if it is determined that the upper electrode film 2 is linearlydriven and the position difference value of the anode catalyst electrodelayer 5 and the cathode catalyst electrode layer 7 is not 0, thecontroller 90 may apply the operation control signal to the vacuum pump42 connected to the lower adsorbent 32 and the driver 51.

According to the manufacturing device 100 of the membrane-electrodeassembly for the fuel cell according to an exemplary embodiment of thepresent disclosure and the manufacturing method thereof, without thechange of the position of the upper and lower bonding rolls 11 and 12,the membrane-electrode assembly may be manufactured while automaticallyaligning the transfer position of the catalyst electrode layers 5 and 7of the upper and lower electrode films 2 and 4.

Accordingly, in an exemplary embodiment of the present disclosure, theposition deviation of the catalyst electrode layers 5 and 7 due to thedriving speed difference of the upper and lower electrode films 2 and 4and the coating position distribution of the catalyst electrode layers 5and 7 may be corrected, the transfer uniformity of the catalystelectrode layers 5 and 7 may be improved and the good quality of themembrane-electrode assembly may be obtained, and the productivity of themembrane-electrode assembly may be further improved.

DESCRIPTION OF SYMBOLS

1 . . . membrane-electrode assembly 2, 4 . . . upper, lower electrodefilm

3 . . . electrolyte membrane 5 . . . anode catalyst electrode layer

6 . . . release bar 7 . . . cathode catalyst electrode layer

9 . . . sub-gasket 11, 12 . . . upper, lower bonding roll

31, 32 . . . upper, lower adsorbent 33, 34 . . . case

37 . . . air hole 41, 42 . . . vacuum pump

45 . . . base frame 51 . . . driver

53 . . . servo motor 54 . . . fixing block

55 . . . lead screw 57 . . . moving block

59 . . . guide block 61, 62 . . . upper, lower position sensor

90. . . . controller 100 . . . manufacturing device

What is claimed is:
 1. A manufacturing method of a membrane-electrodeassembly for a fuel cell bonding each of anode and cathode catalystelectrode layers continuously formed in upper and lower electrode filmsto upper and lower surfaces of an electrolyte membrane, the methodcomprising: unwinding the electrolyte membrane of a roll shape to besupplied to a predetermined transport path; unwinding the upper andlower electrode films of the roll shape continuously coated with theanode and cathode catalyst electrode layers with a predeterminedinterval to be supplied to upper and lower sides of the electrolytemembrane; sensing a position of the catalyst electrode layers for theupper and lower electrode films through upper and lower position sensorsto output a detection signal thereof to a controller; operating a vacuumpump connected to at least one of the upper absorbent, the loweradsorbent and the driver, depending on a detection signal of the upperand lower position sensors through the controller; vacuum-adsorbing atleast one of the upper and lower electrode films through at least one ofthe upper and lower adsorbents, and moving said at least one of theupper and lower adsorbent through the driver in a feed direction of theelectrolyte membrane and the upper and lower electrode films to alignthe position of the catalyst electrode layers; and transferring thecatalyst electrode layers of the upper and lower electrode films to theupper surface and the lower surface of the electrolyte membrane at apredetermined temperature while passing the electrolyte membrane and theupper and lower electrode films between the upper and lower bondingrolls.
 2. The manufacturing method of claim 1, wherein the controllercalculates a position difference value of the catalyst electrode layersdepending on a driving speed of the upper and lower electrode films withreference to a position sensing time difference of the upper and lowerposition sensors, and applies an operation control signal to the vacuumpump connected to at least one of the upper and lower adsorbents and thedriver when the position difference value is not
 0. 3. The manufacturingmethod of claim 2, wherein the controller applies the operation controlsignal to the vacuum pump connected to at least one of the upper andlower adsorbents and the driver with a reference to the detection signalof the upper and lower position sensors firstly sensing the position ofthe catalyst electrode layers of the upper and lower electrode films. 4.The manufacturing method of claim 3, wherein the controller applies theoperation control signal to the vacuum pump connected to the upperadsorbent and the driver if the detection signal of the lower positionsensor is first received.
 5. The manufacturing method of claim 4,wherein: the upper adsorbent vacuum-adsorbs the upper electrode film bythe vacuum pump; and the driver moves the upper adsorbent by a distancecorresponding to the position difference value along the feed directionof the electrolyte membrane and the upper and lower electrode films. 6.The manufacturing method of claim 5, wherein the controller applies theoperation control signal to the vacuum pump to stop the operation of thevacuum pump when the position difference value is 0, and applies theoperation control signal to the driver to return the upper adsorbent toa predetermined initial position through the driver.
 7. Themanufacturing method of claim 3, wherein the controller applies theoperation control signal to the vacuum pump connected to the loweradsorbent and the driver when the detection signal of the upper positionsensor is first received.
 8. The manufacturing method of claim 7,wherein: the lower adsorbent vacuum-adsorbs the lower electrode film bythe vacuum pump; and the driver moves the lower adsorbent by thedistance corresponding to the position difference value along the feeddirection of the electrolyte membrane and the upper and lower electrodefilms.
 9. The manufacturing method of claim 8, wherein the controllerapplies the operation control signal to the vacuum pump to stop theoperation of the vacuum pump when the position difference value is 0,and applies the operation control signal to the driver to return thelower adsorbent through the driver to a predetermined initial position.10. The manufacturing method of claim 1, wherein the upper and lowerposition sensors photograph each catalyst electrode layer for the upperand lower electrode films, and output data thereof to the controller.11. The manufacturing method of claim 10, wherein the controlleranalyzes vision data transmitted from the upper and lower positionsensors to calculate a position difference value of the catalystelectrode layers for the upper and lower electrode films, and appliesthe operation control signal to the vacuum pump connected to at leastone of the upper and lower adsorbents and the driver if it is determinedthat the position difference value is not 0.